Seat having a web stacked in a widthwise direction of the seat

ABSTRACT

A seat which can obtain a favorable sitting feeling using a fibrous structure is provided. A seat  1  is provided with a cushion body  11  comprising fibrous structures  4   a  to  4   d  and a seat frame  15  supporting the cushion body  11 , in which the fibrous structures  4   a  to  4   d  are formed by stacking a web  2  so that the web  2  extends along a thickness direction T of the fibrous structures, the cushion body  11  is formed so that the thickness direction T of the fibrous structure  4   a  is along a load direction applied on the cushion body  11  at sitting, and a stacking direction of the web  2  constituting the fibrous structure  4   a  is along a widthwise direction W of the cushion body  11 . Since the web  2  easily falls down along the widthwise direction W of the cushion body due to a load of a seat occupant, the cushion body as a whole is in a shape curved along the widthwise direction W around a region where the load is applied, and the body of the seat occupant is supported as if being surrounded from both sides in the widthwise direction W. Thus, the seat occupant can obtain a soft touch feeling.

TECHNICAL FIELD

The present invention relates to a seat, and in particular to a seat using a fibrous structure composed of polyester fibers or the like, and a method of manufacturing the same.

BACKGROUND ART

Conventionally, a seat using a fibrous structure composed of polyester fibers or the like as a cushion body has been known (for example, see Patent Document 1 cited below). The fibrous structure used in the seat described in Patent Document 1 is formed by successively folding a web obtained by dispersing and incorporating thermally adhesive composite short fibers as an adhesive component into matrix fibers composed of an inelastic polyester crimped short fiber assembly in a standing state along its longitudinal direction. That is, this fibrous structure is formed to have a predetermined thickness by folding the web in an accordion shape.

In this seat, each of a seat portion and a seat back portion is constituted by stacking a plurality of the fibrous structures to form a cushion body and coating this cushion body with a cover. Accordingly, in this seat, since the standing direction of the web (a thickness direction of the cushion body) is directed along a load direction during sitting of a seat occupant, excellent ventilation is, of course, favorable, a proper hardness to a load direction is provided, and load can be dispersed. Therefore, this seat can provide a soft touch feeling which cannot be obtained by urethane conventionally used in general.

Patent Document 1: Japanese Patent Laid Open Publication No. 1996(H08)-318066

DISCLOSURE OF THE INVENTION Problem to be Solved by the Invention

Since the seat described in Patent Document 1 has a structure such that a longitudinal direction of the fibers extends along a load direction, it can support a sufficient load while maintaining a soft touch feeling as mentioned above. However, in the seat, since the longitudinal direction (combing direction or web stacking direction) of the accordion-shaped fibrous structure is disposed in the front and rear direction in the seat portion and in the vertical direction in the seat back portion, there is a region where the cushion body is hard to flex (or hard to sink) at sitting. Thus, in this seat, a somewhat hard sitting feeling is obtained from this region, and there is a fear that a favorable sitting feeling can not be felt. The problem of a conventional seat disclosed in Patent Document 1 will be described in more detail referring to the attached drawings.

FIG. 12 is an explanatory diagram illustrating an entire view of a conventional seat, and FIG. 13 is an explanatory diagram illustrating a sectional shape of a cut-out region R in FIG. 12. As shown in FIG. 12, the conventional seat 101 comprises a seat portion 110 having a sitting surface 110 a on which a seat occupant sits and a seat back portion 120 on which the back of the seat occupant leans. The seat portion 110 comprises a cushion body 111, a cover 113, and a seat frame 115. In this figure, a widthwise direction of the seat portion 110 is indicated by W, a lengthwise direction by L, and a thickness direction by T.

As shown in FIG. 13, in the cushion body 111 of this seat portion 110, a web 102 is formed by being folded in an accordion shape. The folding direction, that is, the stacking direction of the web 102 extends along the lengthwise direction L of the seat portion 110 and crosses the widthwise direction W at a right angle. When a seat occupant sits on the sitting surface 110 a of the seat portion 110, a force toward the vertically downward direction, that is, load in the vertically downward direction of the thickness direction T is applied on the cushion body 111. Since the web 102 is in the standing state along the thickness direction T, the fibers are compressed in the load direction (that is, the vertically downward direction of the thickness direction T) upon receipt of the load. Thus, a portion having received the load in the sitting surface 110 a is flexed in the load direction.

However, in this conventional seat 101, the longitudinal direction (that is, the stacking direction) of the web 102 constituting the cushion body 111 extends along the lengthwise direction L of the seat portion 110, while the lateral direction of the web 102 extends along the widthwise direction W of the seat portion 110. Since the lengthwise direction L is the stacking direction of the web 102 and there are many gaps between the standing structure of the web 102, the web 102 easily falls down along the lengthwise direction L centering on the region having received the load. On the other hand, since the widthwise direction W is the direction orthogonal to the standing structure of the web 102 (that is, the lateral direction of the web 102), there are few gaps and the web 102 is hard to fall down in the direction along the widthwise direction W from the load center. Accordingly, the center part (A1 in FIG. 12) on which the load is applied and a peripheral portion (A2 and A3 in FIG. 12) along its widthwise direction W of the seat portion 110 are largely flexed, but a flexing amount is small in a region (B1, C1 in FIG. 12) far from the load center part along the lengthwise direction L and a region (C1 in FIG. 12) to which the upper part on the back of the buttocks abuts, so that a soft touch feeling such as surrounding the body is lacking, and a favorable sitting feeling can not be obtained.

An object of the present invention is to provide a seat which can give a favorable sitting feeling using a fibrous structure with a predetermined thickness folded in a standing state.

Means for Solving the Problem

A seat according to an embodiment of the present invention is a seat provided with a cushion body made from a fibrous structure and a seat frame supporting the cushion body, in which the fibrous structure is obtained by stacking a web such that an extending direction of the web conforms with a thickness direction of the fibrous structure, and regarding the cushion body, the thickness direction of the fibrous structure extends along a load direction applied on the cushion body at sitting, while the stacking direction of the web constituting the fibrous structure extends along the widthwise direction of the cushion body.

Thus, according to the seat of an embodiment of the present invention, since the web is stacked so that the thickness direction of the fibrous structure extends along the extending direction of the web, upon receipt of an external load caused by contact with the body of a seat occupant such as buttocks and back at sitting, the web falls down and largely flexes in the load direction. Thus, it becomes possible to give a soft touch feeling to the seat occupant at sitting. Moreover, since the seat is formed so that the stacking direction of the web constituting the fibrous structure extends along the widthwise direction of the cushion body, the web easily falls down along the widthwise direction of the cushion body by the load of the seat occupant. Thus, if the load is applied on the cushion body due to sitting of the seat occupant, the web falls down toward the widthwise direction centering on a region on which the load is applied, and the cushion body as a whole is brought into a shape curved in the widthwise direction around the region having received the load. Accordingly, the body of the seat occupant is supported as if being surrounded from both sides in the widthwise direction, by which the seat occupant can obtain the soft touch feeling.

The cushion body is supported by the seat frame on both side portions in the widthwise direction.

Thus, since the seat of an embodiment of the present invention is supported by the seat frame on both side portions in the widthwise direction of the cushion body, though the center part in the widthwise direction is largely flexed toward the load direction, a flexing amount on both side portions is small. Thus, the body of the seat occupant is supported as if being surrounded from both sides in the widthwise direction, by which the seat occupant can obtain the soft touch feeling.

Effect of the Invention

According to an embodiment of the present invention, since the web is formed so that the stacking direction of the web constituting the fibrous structure extends along the widthwise direction of the cushion body, the web easily falls down along the widthwise direction of the cushion body by the load of the seat occupant, and thus, if the load from the body of the seat occupant is applied on the cushion body due to sitting of the seat occupant, the cushion body largely flexes centering on the region on which the load is applied in the widthwise direction, and the body of the seat occupant is supported as if being surrounded from both sides in the widthwise direction. Accordingly, the seat occupant can obtain the soft touch feeling, by which a favorable sitting feeling can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an explanatory view of a seat according to an embodiment of the present invention.

FIG. 2 is an explanatory diagram of a fiber direction of a web according to an embodiment of the present invention.

FIG. 3 is an explanatory diagram of a manufacturing step of a sheet-like fibrous structure according to an embodiment of the present invention.

FIG. 4 is an explanatory diagram of the sheet-like fibrous structure before stacked according to an embodiment of the present invention.

FIG. 5 is an explanatory view of a mold according to an embodiment of the present invention.

FIG. 6 is an explanatory diagram of a manufacturing step of a cushion body according to an embodiment of the present invention.

FIG. 7 is an explanatory diagram of a manufacturing step of the cushion body according to an embodiment of the present invention.

FIG. 8 is a sectional explanatory diagram of the cushion body according to an embodiment of the present invention.

FIG. 9 is an explanatory diagram illustrating a sectional shape of a region R cut out in FIG. 1.

FIG. 10 is an explanatory diagram of the region S in FIG. 8 in an enlarged manner.

FIG. 11 is sectional views showing a state that a seat portion of a seat has been cut in a widthwise direction.

FIG. 12 is an explanatory diagram illustrating an entire view of a conventional seat.

FIG. 13 is an explanatory diagram illustrating a sectional shape of a region R cut out from FIG. 12.

EXPLANATION OF REFERENCE NUMERALS

-   1: seat -   2: web -   4 a: first sheet-like fibrous structure (fibrous structure) -   4 b: second sheet-like fibrous structure (fibrous structure) -   4 c: U-shaped sheet-like fibrous structure -   4 d: protrusion type sheet-like fibrous structure -   10: seat portion -   10 a: sitting surface (load receiving face) -   10 b: back surface (non-load receiving face) -   11, 21: cushion body -   13, 23: cover -   15, 25: seat frame -   17: trim cord -   19: engagement portion -   20: seat back portion -   40: mold -   40 a: cavity -   41: first mold -   42: second mold -   43: steam hole -   50: high pressure steam molding machine -   61: driving roller -   62: hot air suction type heat treating machine -   101: seat -   102: web -   110: seat portion -   110 a: sitting surface -   111: cushion body -   113: cover -   115: seat frame -   120: seat back -   a: fiber constituting web -   b: lengthwise direction of web -   c: fiber direction constituting web -   θ: angle of lengthwise direction of fiber to lengthwise direction of     web

BEST MODE FOR CARRYING OUT THE INVENTION

One embodiment of the present invention will be explained below with reference to the drawings. Incidentally, parts, arrangements or the like explained below do not limit the present invention, and the present invention can be modified variously within the scope and spirit of the present invention.

FIG. 1 to FIG. 11 show an embodiment of the present invention, FIG. 1 being an explanatory diagram of a seat, FIG. 2 being an explanatory diagram of a fiber direction in a web, FIG. 3 being an explanatory diagram of a manufacturing step of a sheet-like fibrous structure, FIG. 4 being an explanatory diagram of the sheet-like fibrous structure before stacked, FIG. 5 being an explanatory diagram of a mold, FIG. 6 and FIG. 7 being explanatory diagrams of a manufacturing step of a cushion body, FIG. 8 being a sectional explanatory diagram of the cushion body, FIG. 9 being an explanatory diagram illustrating a sectional shape of a region R cut out in FIG. 1, FIG. 10 being an explanatory diagram illustrating the region S in FIG. 8 in an enlarged manner, and FIG. 11 being sectional views showing a state that a seat portion of the seat has been cut in a widthwise direction thereof.

A seat 1 of the embodiment can be applied to a seat for a vehicle, a train, an airplane or the like, and it may be also applied to various chairs such as a business chair or a care chair. The seat 1 of this embodiment is provided with a seat portion 10 and a seat back portion 20, as shown in FIG. 1. The seat portion 10 and the seat back portion 20 are respectively constituted such that cushion bodies 11 and 21 are placed on seat frames 15 and 25 and the cushion bodies 11 and 21 are coated with covers 13 and 23.

Regarding the cushion body of this embodiment, a forming step (a cushion body forming step) thereof will be explained taking the cushion body 11 of the seat portion 10 as an example. The cushion body 21 is also formed according to a similar method as the above. The cushion body 11 in this embodiment is formed by forming a sheet-like fibrous structure as a fibrous structure where a web 2 has been folded in a standing state (a fibrous structure forming step) described later, cutting this sheet-like fibrous structure into fibrous structure pieces with predetermined shapes to stack a plurality of cut fibrous structure pieces and disposing the plurality of cut fibrous structure pieces in a mold 40 formed with a plurality of steam holes 43 which are ventilation holes on its mold face (a fibrous structure disposing step), and performing high pressure steam molding in high pressure steam molding machine 50 in which the mold 40 has been clamped (a molding step).

First, the web 2 for forming the cushion body 11 of this embodiment will be explained with reference to FIG. 2 and FIG. 3. The web 2 is one obtained by dispersing and mixing matrix fibers composed of assemblies of inelastic crimped short fibers, and thermally adhesive composite short fibers having a melting point lower than that of the inelastic crimped short fibers and having a melting point of at least 120° C. as an adhesive component.

The web 2 in this embodiment is one obtained by performing cotton blending of inelastic polyester crimped short fibers as the inelastic crimped short fibers and the thermally adhesive composite short fibers composed of thermoplastic elastomer having a melting point lower than a melting point of polyester polymer constituting the inelastic polyester crimped short fibers by 40° C. and inelastic polyester such that the fibers are mainly directed in a longitudinal direction of the web 2. The web 2 of this embodiment has a bulk property of at least 30 kg/m³ and it is formed with cubic fiber crossing points between the thermally adhesive composite short fibers and between the thermally adhesive composite short fibers and the inelastic polyester crimped short fibers.

In this embodiment, hollow polyethylene terephthalate fibers with a single yarn fineness of 12 deniers and a fiber length of 64 mm, which have a cubic crimp due to anisotropic cooling, are used as the inelastic polyester crimped short fibers. As the inelastic polyester crimped short fibers, the short fibers are made from ordinary polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, polypivalolactone, or copolymer ester thereof, cotton blended material of these fibers, composite fibers composed of two or more kinds of the above polymer components, or the like can be used. Short fibers of polyethylene terephthalate, polytrimethylene terephthalate, or polybutylene terephthalate of these short fibers are desirable. Further, potential crimped fibers composed of two kinds of polyethylene terephthalate and polytrimethylene terephthalate whose inherent viscosities are different from each other or a combination thereof, where crimps have micro-crimps due to heat treatment or the like can also be used.

Further, a sectional shape of the short fiber may be circular, oval, hyterotypic, or hollow. A thickness of this short fiber is in a range of 2 to 200 deniers, especially, preferably in a range of 6 to 100 deniers. Incidentally, when the thickness of the short fiber is small, softness increases, but elasticity of the cushion body often lowers.

Further, when the thickness of the short fiber is excessively thick, handling easiness, especially, formability of the web 2 deteriorates. Furthermore, there is a possibility that, as the number of constituent fibers decreases excessively, the number of crossing points formed between the short fibers and the thermally adhesive composite short fibers also decreases so that elasticity of the cushion body is hard to develop and simultaneously durability lowers. Furthermore, texture becomes excessively rough and hard.

In the embodiment, as the thermally adhesive composite short fibers, core/sheath type thermally melting composite fibers (a core/sheath ratio=60/40: weight ratio) with a single yarn fineness of 6 deniers and a fiber length of 51 mm, which uses thermoplastic polyether ester elastomer with a melting point of 154° C. as a sheath component and uses polybutylene terephthalate with a melting point of 230° C. as core component are used.

The thermally adhesive composite short fibers are composed of thermoplastic elastomer and inelastic polyester. Then, it is preferable that the former occupies at least ½ of a fiber surface. Regarding a weight ratio, it is appropriate that the former and the latter are in a range of 30/70 to 70/30 in a composite ratio. The thermally adhesive composite short fibers may be of a side by side type or of a sheath-core type, but the latter is desirable. In the sheath-core type, the inelastic polyester constitutes the core, but the core may be concentric or eccentric. Especially, the eccentric type is more desirable because coil-like elastic crimps are developed.

As the thermoplastic elastomer, polyurethane elastomer or polyester elastomer is desirable. Especially, the latter is appropriate. As the polyurethane elastomer, polyol with a low melting point having a molar weight of about 500 to 6000, for example, dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, or the like, organic diisocyanate with a molar weight of 500 or less, for example, p,p-diphenylmethane diisocyanate, tolylene diisocyanate, isophorone diisocyanate, diphenylmethane diisocyanate hydride, xylylene diisocyanate, 2,6-diisocyanate methyl caproate, hexamethylene diisocyanate, or the like, chain extender with a molar weight of 500 or less, for example, polymer obtained by reaction with glycol, amino alcohol, or triol are used. An especially desirable one of these polymers is polytetramethylene glycol as polyol, or polyurethane using poly-ε-caprolactone or polybutylene adipate. In this case, p,p′-diphenylmethane diisocynate is desirable as an organic diisocyanate. Further, p,p′-bidihydroxy-ethoxy benzene and 1,4-butane diol are desirable as the chain extender.

On the other hand, as the polyester elastomer, polyether ester block copolymer obtained by performing copolymerization using thermoplastic polyester as a hard segment and using poly (alkylene oxide) glycol as a soft segment, more specifically, temary copolymer composed of at least one of dicarboxylic acids selected from aromatic dicarboxylic acid such as terephthalic acid, isophthalic acid, phthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, diphenoxy-ethane dicarboxylic acid, or 3-sodium sulfoisophthalic acid, alicyclic dicarboxylic acid such as 1,4-cyclohexane dicarboxylic acid, aliphatic dicarboxylic acid such as succinate, oxalic acid, adipic acid, sebacic acid dodecanedioic acid, dimer acid, ester-forming derivatives thereof, or the like; at least one of diol components selected from aliphatic diol such as 1,4-butane diol, ethylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, neopentyl glycol, or decamethylene glycol, or alicyclic diol such as 1,1-cyclohexan dimethanol, 1,4-cyclohexan dimethanol, or tricyclodecane dimethanol, ester-forming derivatives thereof, or the like; and at least one of poly (alkylene oxide) glycol such as polyethylene glycol, poly (1,2- and 1,3-propylene oxide) glycol, poly (tetramethylene oxide) glycol, copolymer of ethylene oxide and propylene oxide, copolymer of ethylene oxide and tetrahydrofuran, or the like, where an average molecular weight is in a range of about 400 to 5000 is used.

Considering the aspect of the adhesiveness, temperature property, and strength of the inelastic polyester crimped short fibers, block copolymerization polyether polyester using polybutylene terephthalate as a hard segment and using polyoxybutylene glycol as a soft segment is desirable. In this case, the polyester component constituting the hard segment includes terephthalic acid as the main acid component, and polybutylene terephthalate which is butylene glycol component as the main diol component. Of course, a portion (generally, 30 mol % or less) of this acid component may be replaced with another dicarboxylic acid component or oxycarboxylic acid component, and similarly a portion (generally, 30 mol % or less) of the glycol component may be replaced with a dioxy component other than the butylene glycol component.

Further, the polyether portion constituting the soft segment may be polyether replaced with a dioxy component other than butylene glycol. Incidentally, various stabilizers, ultraviolet absorbent, thickening branching agent, delusterant, colorant, or other various improvers or the like may be blended in the polymer according to necessity.

It is preferable that the degree of polymerization of the polyester elastomer is in a range of 0.8 to 1.7 dl/g, especially, in a range of 0.9 to 1.5 dl/g regarding inherent viscosity. If this inherent viscosity is excessively low, a heat adhesion spot formed by the inelastic polyester crimped short fibers constituting the matrix is made breakable. On the other hand, if the inherent viscosity is excessively high, a spindle-shaped node becomes hard to be formed at a heat adhesion time.

As basic characteristics of the thermoplastic elastomer, a fracture elongation is preferably 500% or more, more preferably, 800% or more. If this elongation is excessively low, when the cushion body 11 is compressed and the deformation reaches the heat adhesion point, the coupling at this portion becomes breakable.

On the other hand, an elongation stress of the thermoplastic elastomer at 300% elongation is preferably 0.8 kg/mm² or less, more preferably, 0.8 kg/mm². If this stress is excessively large, it becomes hard for the heat-adhesion spot to disperse force applied on the cushion body 11, so that, when the cushion body 11 is compressed, the heat-adhesion spot may be broken by the force applied at that time, or even if it is not broken, the inelastic polyester crimped short fibers constituting the matrix may be also strained or crimps may fatigue.

Further, the elongation recovery ratio of the thermoplastic elastomer at 300% elongation is preferably 60% or more, more preferably, 70% or more. When this elongation recovery ratio is low, even if the cushion body 11 is compressed so that the heat-adhesion spot is deformed, recovery to its original state may become hard. It is required that these thermoplastic elastomers have melting points lower than the polymer constituting the inelastic polyester crimped short fibers and they do not cause crimps of the crimped short fibers to thermally fatigue at a hot-melting processing time for forming the heat-adhesion spot. Therefore, the melting point is preferably lower than the melting point of the polymer constituting the short fibers by 40° C. or more, more preferably, by 60° C. or more. Such a melting point of the thermoplastic elastomer can be set to a temperature in a range of 120 to 220° C., for example.

When the difference in melting point is smaller than 40° C., a heat treatment temperature at a melting processing time described later is excessively high, and fatigue of crimps of the inelastic polyester crimped short fibers is caused, which results in lowering of mechanical properties of the crimped short fibers. Incidentally, regarding the thermoplastic elastomer, when its melting point can not be observed clearly, a softening point thereof is observed instead of the melting point.

On the other hand, as the inelastic polyester crimped short fibers used as a mating component of the thermoplastic elastomer in the composite fibers, polyester polymers constituting the crimped short fibers forming the matrix, such as described above, are adopted, but polyethylene terephthalate, polymethylene terephthalate, or polybutylene terephthalate is more preferably adopted among them.

The above-described composite fibers are dispersed and blended in a range of 20 to 100%, preferably, 30 to 80% based upon weight of the web 2. In the web 2 in this embodiment, the thermally adhesive composite short fibers as the binder fibers and the inelastic crimped short fibers as the main fibers are cotton-blended at a weight ratio of 60:40.

When the dispersion and blend ratio of the composite fibers is excessively low, the number of heat-adhesion spots is reduced, so that the cushion body 11 may become easily deformable, or elasticity, repulsive property, and durability may lower. Further, cracks between tops arranged may occur.

In the embodiment, the inelastic polyester crimped short fibers and the thermally adhesive composite short fibers are cotton-blended at the weight ratio of 40:60, and they are formed in the web 2 of coating weight 20 g/m² through a roller card.

The web 2 in this embodiment is formed such that a ratio of fibers oriented in the lengthwise direction of the web is relatively higher than that of fibers oriented in a lateral direction. That is, the web 2 in this embodiment is formed so as to satisfy a relationship of C≧3D/2, preferably, C≧2D per unit volume. When the total numbers of the fibers C oriented in the lengthwise direction (a continuous direction) in this continuous web 2 and the fibers D oriented in the lateral direction (a widthwise direction of the web) are examined, it can be confirmed that C:D=2:1.

Here, as shown in FIG. 2, the fibers oriented in the lengthwise direction of the web 2 are fibers satisfying such a condition that an angle θ of the lengthwise direction of the fibers to the lengthwise direction of the web is in a range of 0°≦θ≦45°, while the fibers oriented in the lateral direction (the widthwise direction of the web) are fibers satisfying such a condition that the angle θ is in a range of 45°<θ≦90°. In the figure, reference symbol a represents fibers constituting the web, reference symbol b represents the lengthwise direction (extending direction) of the web, and reference symbol c represents the fiber direction constituting the web. Further, regarding the orientation of the fibers constituting the sheet-like fibrous structure, a thickness direction of the sheet-like fibrous structure and a direction extending along a direction perpendicular to a thickness direction thereof mean directions within a range of ±45° to these directions.

A direction where each fiber direction can be observed by extracting random portions in a surface layer portion and an inner layer portion of the web 2 to observe them using a transmission type optical microscope. Incidentally, the thickness of the web 2 is 5 mm or more, preferably, 10 mm or more, further preferably 20 mm or more. Generally, the web 2 has a thickness of 5 to 150 mm.

Next, the web 2 formed such that fibers mainly extend along the lengthwise direction is folded like an accordion such that it has a predetermined density and a desired thickness as a structural body, so that cubic fiber crossing points are formed between the composite fibers and between the inelastic polyester crimped short fibers and the composite fibers, and heat treatment is then performed at a temperature (to 80° C.) lower than the melting point of the polyester polymer and higher than the melting point (or a fluidization start point) of the thermoplastic elastomer, so that elastomer components are melt-adhered at the fiber crossing points and flexible heat-adhesion spots are formed.

Specifically, as shown in FIG. 3, the web 2 is folded to an accordion shape by pushing the web 2 into a hot-air suction type heat treatment machine 62 (a length of a heat treatment zone is 5 m and a moving velocity is 1 m/min) by a driving roller 61 with a roller surface velocity of 2.5 m/min and it is formed in a heat-adhered sheet-like fibrous structure with a thickness of 25 mm by treating the web 2 at 190° C. for 5 minutes using Struto equipment (a fibrous structure forming step).

Adhesion spots thermally adhering in a state the thermally adhesive composite short fibers have crossed one another and adhesion spots thermally adhering in a state that the thermally adhesive composite short fibers and the inelastic crimped short fibers have crossed one another are dispersed in the sheet-like fibrous structure thus formed. It is appropriate for developing cushioning properties, ventilation properties, and elasticity that the density of the sheet-like fibrous structure is in a range of 5 to 200 kg/m³.

By forming the web 2 formed such that their fibers extend along the lengthwise direction in a folding manner, the sheet-like fibrous structure is formed such that the number of fibers oriented in the thickness direction is larger than that of fibers oriented in a direction perpendicular to this thickness direction and a direction of the fibers mainly becomes parallel to the thickness direction. That is, the sheet-like fibrous structure in the embodiment is formed such that when the total number of fibers arranged along in the thickness direction is represented as A and the number of fibers arranged along the direction perpendicular to the thickness direction is represented as B regarding per unit volume, a relationship of A≧3B/2, preferably, A≧2B is satisfied.

Next, the sheet-like fibrous structure is cut in a predetermined shape, and cut pieces are stacked in a vertical direction (a thickness direction T), as shown in FIG. 4. In this embodiment, four kinds of sheet-like fibrous structures 4 a to 4 d including a first sheet-like fibrous structure 4 a, a second sheet-like fibrous structure 4 b, a U-shaped sheet-like fibrous structure 4 c with a U shape for forming a bank portion of the cushion body 11, and a protrusion-shaped sheet-like fibrous structure 4 d for forming a protrusion portion to be slightly protruded between both thighs of a seat occupant are respectively cut in predetermined shapes, the U-shaped sheet-like fibrous structure 4 c and the protrusion-shaped sheet-like fibrous structure 4 d are sandwiched between the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b. Incidentally, a widthwise direction of the cushion body 11, a lengthwise direction thereof, and a thickness direction thereof are represented as W, L, and T in FIG. 4, respectively.

In this embodiment, the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b having equivalent fiber material and fiber density to those of the first sheet-like fibrous structure 4 a are stacked on its lower face. In this embodiment, the fiber density of the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b is in a range of 5 to 35 kg/m³ before thermal molding. Incidentally, the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b correspond to the fibrous structure of the present invention.

As described above, the first sheet-like fibrous structure 4 a is formed of a sheet-like fibrous structure obtained by folding the web 2 obtained by blending the main fibers and the binder fibers in a standing state. The first sheet-like fibrous structure 4 a is arranged on a side (an upper side in FIG. 4) of a sitting surface 10 a of the seat 1, and it serves to receive load from the body of a seat occupant directly or indirectly via a cover. The thickness of the first sheet-like fibrous structure 4 a may be a desired thickness according to the shape of the cushion body 11. It is set to a desired thickness in a range of approximately 10 to 40 mm, for example. The direction of the first sheet-like fibrous structure 4 a is determined so that the stacking direction of the web 2 extends along the widthwise direction (W direction in the figure).

The second sheet-like fibrous structure 4 b is formed of a sheet-like fibrous structure made from substantially the same fiber material as that of the first sheet-like fibrous structure 4 a. The second sheet-like fibrous structure 4 b is arranged on the side (a lower side in FIG. 4) of the seat frame 15 of the seat 1. The thickness of the second sheet-like fibrous structure 4 b may be also a desired thickness similarly to the first sheet-like fibrous structure 4 a. The stacking direction of the web 2 in the second sheet-like fibrous structure 4 b may be such that the stacking direction of the web 2 is the widthwise direction W similarly to the first sheet-like fibrous structure 4 a, but it is preferable that the direction is the lengthwise direction L, contrary to the stacking direction of the first sheet-like fibrous structure 4 a. With such arrangement, the lateral directions of the webs 2 in the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b become orthogonal to each other, by which the web of the first sheet-like fibrous structure 4 a which has sunk upon receipt of a load is easily supported by the web of the second sheet-like fibrous structure 4 b, and thus, the cushion body 11 does not flex excessively in the load direction and durability against fatigue and the like can be improved.

Between the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b, the U-shaped sheet-like fibrous structure 4 c and the protrusion-shaped sheet-like fibrous structure 4 d are disposed. The U-shaped sheet-like fibrous structure 4 c is a fibrous structure for forming a bank portion of the cushion body 11 as will be described later, and the protrusion-shaped sheet-like fibrous structure 4 d is a fibrous structure for forming a protrusion portion of the cushion body 11.

These sheet-like fibrous structures 4 a to 4 d are stacked in their thickness direction T. That is, stacking is performed such that a direction of fibers extends in a vertical direction. Further, holt-melt films, hot-melt unwoven cloths, hot-melt adhesives, or the like are arranged at portions where the sheet-like fibrous structures 4 a to 4 d abut on one another according to necessity.

The sheet-like fibrous structures 4 a to 4 d thus stacked are arranged in a mold 40 such as shown in FIG. 5 and compressed (a fibrous structure arranging step). The mold 40 of this embodiment is composed of a first mold 41 and a second mold 42. The first mold 41 is a mold used to form a shape of the cushion body 11 positioned on the side of the sitting surface 10 a (namely, a surface), while the second mold 42 is a mold used to form a shape of the cushion body 11 positioned on the side of the seat frame 15, namely, on the side of a back surface 10 b (a non-load receiving face). When the first mold 41 and the second mold 42 are fastened, a cavity 40 a having a desired undulation shape of the cushion body 11 is formed. Further, steam holes 43 are formed on a portion or a whole of a mold face of the mold 40. In the embodiment, the steam holes are hardly formed on the first mold 41 while a plurality of steam holes 43 are bored over a whole face of the second mold 42 in the second mold 42. The mold 40 can be formed using such metal as iron, steel, aluminum, glass fiber, or carbon fiber, or it may be formed of any synthetic resin.

FIG. 6 is a sectional view of a state that the sheet-like fibrous structures 4 a to 4 d have been disposed in the mold 40 and the mold 40 has been fastened. The sheet-like fibrous structures 4 a to 4 d are formed to be larger than the cavity 40 a of the mold 40 in a natural state by about 1.2 to 3.0 times in volume. Accordingly, the sheet-like fibrous structures 4 a to 4 d are changed to a state that they have been compressed to the shape of the cavity 40 a at a mold fastening time.

The first sheet-like fibrous structure 4 a is received in the cavity 40 a such that an upper face thereof abuts on an inner wall face of the first mold 41. Further, the second sheet-like fibrous structure 4 b is arranged in the cavity 40 a such that a lower face thereof abuts on an inner wall portion of the second mold 42. The U-shaped sheet-like fibrous structure 4 c and the protrusion-shaped sheet-like fibrous structure 4 d are disposed between the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b.

Next, as shown in FIG. 7, the mold 40 in which the sheet-like fibrous structures 4 a to 4 d have been disposed is entered into a high pressure steam molding machine 50. A steam introducing port (not shown) is formed on an upper portion of the high pressure steam molding machine 50, so that high pressure steam can be introduced from the outside of the high pressure steam molding machine 50 into the high pressure steam molding machine 50. The mold 40 is installed in the high pressure steam molding machine 50 such that the second mold 42 is directed vertically upwardly and the first mold 41 is directed vertically downwardly. After steam is blown to the mold 40, cooling and mold-releasing are performed to obtain the cushion body 11 (cooling and mold-releasing step).

In the molding step of this embodiment, a temperature inside the high pressure steam molding machine 50 is controlled such that steam with a molding temperature can be blown to the molding 40. Here, the molding temperature is a temperature higher than a melting point of the thermally adhesive composite short fibers serving as the binder fibers, namely, higher than a melting point of thermoplastic elastomer, and lower than a melting point of matrix fibers (the inelastic crimped short fibers) serving as the main fibers. In order to raise a temperature of steam to the molding temperature, a temperature inside the high pressure steam molding machine 50 is first raised to the molding temperature by a heater (not shown) and a pressure inside the high pressure steam molding machine 50 is raised from an ambient air pressure (about 1 atm) to at least saturated steam pressure of steam or higher in the molding temperature.

In this embodiment, since the melting point of the binder fibers is about 154° C., the molding temperature is set to 161° C. that is higher than the melting point. In this embodiment, then, since water vapor (H₂O) serving as heat conduction material is blown to the mold 40, the temperature inside the high pressure steam molding machine 50 is raised up to the molding temperature of 161° C. in about 30 seconds and the pressure inside the high pressure steam molding machine 50 is raised to air pressure of about 5.5 atm (about 0.557 MPa) which is a boiling point at the molding temperature of 161° C. That is, the saturated steam pressure at the molding temperature of 161° C. is about 5.5 atm.

In the molding step, water vapor with the molding temperature is blown to the mold 40 in a state that the temperature and the pressure inside the high pressure steam molding machine 50 have been kept in the molding temperature and a predetermined pressure. In this embodiment, molding is performed by blowing steam to the mold 40 for about one minute and 10 seconds. Thereafter, the temperature inside the high pressure steam molding machine 50 is lowered to the molding temperature or lower in about one minute and the pressure inside the high pressure steam molding machine 50 is reduced to an ambient air pressure. Then, the mold 40 is taken out of the high pressure steam molding machine 50 to be cooled (a cooling step), and the cushion body 11 thermally molded is released from the mold 40 (a mold-releasing step). In this embodiment, tact time for thermally molding the cushion body 11 in the high pressure steam molding machine 50 can be set to about 3 to 5 minutes.

By blowing steam at the molding temperature to the mold in this manner, steam enters in the sheet-like fibrous structures 4 a to 4 d having ventilation properties from steam holes 43 of the mold 40, and it exits from other steam holes 43 to the outside of the mold 40. The sheet-like fibrous structures 4 a to 4 d are disposed in the mold 40 in their compressed state, and crossing points between the thermally adhesive composite short fibers and between the thermally adhesive composite short fibers and the inelastic crimped short fibers are caused to thermally adhere to one another due to steam heat so that the cushion body is formed in the shape of the cavity 40 a of the mold 40.

Further, hot-melt films, hot-melt unwoven clothes, hot-melt adhesives, or the like disposed among the sheet-like fibrous structures 4 a to 4 d are melted due to steam heat and the sheet-like fibrous structures 4 a to 4 d are fixed to one another. Thus, fibers in the sheet-like fibrous structures 4 a to 4 d are caused to thermally adhere to one another due to steam and the sheet-like fibrous structures 4 a to 4 d are fixed to one another by the hot-melt film, a hot-melt unwoven cloth, hot-melt adhesive, or the like, so that a cushion body 11 with a predetermined shape is formed. Incidentally, dish cloth may be inserted on a surface according to necessity, or wires made from steel or the like may be inserted among the sheet-like fibrous structures 4 a to 4 d.

When steam at the molding temperature is blown to the mold 40 inside the high pressure steam molding machine 50 raised up to the saturated steam pressure like this embodiment, a molding time can be largely reduced. That is, since steam at the molding temperature has a thermal capacity larger than that of hot air, the binder fibers can be melted in a short time.

Incidentally, when high pressure steam is blown to the mold under air pressure, since the high pressure steam adiabatically expands immediately and a temperature of the steam lowers, it is difficult to cause steam at the molding temperature to reach inside of the fiber bodies. Therefore, a long molding time is required notwithstanding. Further, in this embodiment, by largely shortening the molding time, a time when fibers are exposed to heat is shortened so that texture of the cushion body 11 molded is made excellent.

In the cushion body 11 of this embodiment, the sheet-like fibrous structures 4 a to 4 d, where the directions of fibers are oriented in the thickness direction T, are stacked and the high pressure steam molding is performed. Accordingly, the fibers constituting the cushion body 11 are arranged along a direction in which load acts when a seat occupant sits on the seat 1. With such a constitution, the cushion body 11 in this embodiment has ventilation properties and can secure a proper hardness to a stress direction, and it provides dispersibility of stress and excellent durability.

Further, the cushion body 11 in this embodiment is molded in a state that it has been compressed by the mold 40, and it can take a three-dimensional and complicated undulation shape so as to conform with the shape of the cavity 40 a of the mold 40. At this time, a cushioning feeling can be adjusted partially according to a compression degree in the mold 40.

The mold 40 in this embodiment is arranged such that the second mold 42 is oriented vertically upwardly, namely, to the side of the steam introducing port. Further, formation is made such that the steam holes 43 of the second mold 42 outnumber the steam holes 43 of the first mold 41. Therefore, an amount of steam introduced from the steam holes 43 of the second mold 42 into the cavity 40 a is more than the amount of steam introduced from the steam holes 43 of the first mold 41. The steam introduced from the steam holes 43 of the second mold 42 is exhausted from the inside of the cavity 40 a through the steam holes formed on a side face of the second mold 42 or the steam holes formed on a side face of the first mold 41. A flow of this steam is indicated by dotted arrows in FIG. 7. Incidentally, in the mold 40 of this embodiment, any steam hole is not formed in a region of the first mold 41 corresponding to the sitting surface 10 a. Thereby, it is made possible to reduce the hardness of the sitting surface 10 a to provide a soft touch feeling to a seat occupant, as described later.

In this embodiment, since the amount of steam introduced from the second mold 42 is more than the amount of steam introduced from the first mold 41, a heat amount supplied to the second sheet-like fibrous structure 4 b disposed on the side of the second mold 42 is more than a heat amount supplied to the first sheet-like fibrous structure 4 a disposed on the side of the first mold 41. When the heat amount to be supplied is much, fibers are melted in a short time by the thermal molding and many fibers are fixed due to heat adhesion so that hardness becomes high. On the other hand, steam holes are hardly formed in the first mold 41 at all, and any steam hole is not formed on a region corresponding to the sitting surface. Therefore, the heat amount supplied to the first sheet-like fibrous structure 4 a is low, and especially, the temperature rise in the region corresponding to the sitting surface becomes very slow. Thus, since the number of fibers fixed by the heat adhesion is reduced in the first sheet-like fibrous structure 4 a, hardness becomes low.

As mentioned above, the first sheet-like fibrous structure 4 a becomes lower in surface layer hardness than the second sheet-like fibrous structure 4 b, and a flexing degree of the former in the thickness direction T to a load due to sitting of a seat occupant becomes large. On the other hand, since the second sheet-like fibrous structure 4 b becomes higher in hardness than the first sheet-like fibrous structure 4 a, durability to load in the thickness direction T due to sitting can be improved. Thus, a cushion body 11 including both a soft touch feeling during sitting and durability to load due to sitting can be provided.

FIG. 8 is a sectional view of the cushion body 11 released from the mold. FIG. 8 shows a sectional shape obtained by cutting the cushion body 11 of the seat 1 shown in FIG. 1 along a direction of arrow line A-A′. As shown in this figure, the cushion body 11 in this embodiment is one thermally molded in a state that the first sheet-like fibrous structure 4 a, the second sheet-like fibrous structure 4 b, the U-shaped sheet-like fibrous structure 4 c with a U shape for forming a bank portion of the cushion body 11, and the protrusion-shaped sheet-like fibrous structure 4 d for forming a protrusion portion to be slightly protruded between both thighs of a seat occupant have been stacked in the thickness direction T. Each of the sheet-like fibrous structures 4 a to 4 d is bonded to each other by hot-melt. In this embodiment, the fiber density of the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b after thermally molded is in a range of about 5 to 35 kg/m³.

FIG. 9 is an explanatory diagram illustrating a sectional shape of a region R in a FIG. 1 cut out. As shown in this figure, in the cushion body 11 in this embodiment, the web 2 is stacked by being folded in an accordion-state, and the stacking direction extends along the widthwise direction of the cushion body 11 (that is, the widthwise direction W of the seat 1). Thus, as shown in FIG. 10, in a region where a load F from the buttocks of a seat occupant is applied at sitting, upon receipt of the load in the thickness direction T, the web 2 falls down and is compressed in the thickness direction T. Accordingly, the cushion body 11 is largely flexed in the load direction along the widthwise direction (that is, the vertically downward direction of the thickness direction T) centering on the region where the load F is received. As shown in this figure, the entire shape of the cushion body is largely flexed in the load direction centering on the region where the load F is received, and in the peripheral region in the widthwise direction, a flexing amount is smaller than that in the center region of the load F, and a curved shape around the center region of the load F is formed as a whole. Thus, the body of the seat occupant is supported as if being surrounded by the cushion body 11 from both sides in the widthwise direction. Accordingly, the seat 1 of this embodiment can give a soft touch feeling to the seat occupant.

Particularly, since even a region in contact with the back side of the thighs of the seat occupant (B1 in FIG. 1) and a region in contact with the upper part on the back of the buttocks (C1 in FIG. 1) are flexed along the widthwise direction upon receipt of the load, a soft touch feeling as if surrounding the body from the both sides can be obtained, by which a favorable touch feeling that can not be obtained from the conventional seat can be gained.

Moreover, as shown in FIG. 1, both side portions in the widthwise direction of the cushion body 11 are supported by the seat frame 15. Thus, though the center part of the cushion body 11 is largely flexed in the load direction upon receipt of the load, since both side portions are supported by the seat frame 15, downward flexing is regulated and a flexing amount in the load direction is small. Thus, the cushion body 11 forms a largely curved shape along the widthwise direction from the load center upon receipt of the load of the seat occupant. As a result, a soft touch feeling as if the body is surrounded by the cushion body 11 from the both side portions can be given to the seat occupant.

Incidentally, in the text, a large flexing degree means a large degree of deformation of the fibrous structure in the load direction in response to an applied load, and specifically it includes both a large degree of reduction in the thickness caused by compression of the fibrous structure in the load direction due to load and a large degree of bending of the entire shape of the plate-state fibrous structure in the load direction. On the contrary, a small flexing degree means a small degree of deformation of the fibrous structure in the load direction due to the applied load, and specifically it includes both a small degree of reduction in the thickness caused by compression of the fibrous structure in the load direction due to load and a small degree of bending of the entire shape of the fibrous structure in the load direction.

The U-shaped sheet-like fibrous structure 4 c is disposed between the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b. The U-shaped sheet-like fibrous structure 4 c in this embodiment is formed from approximately the same material as that for the first sheet-like fibrous structure 4 a or the second sheet-like fibrous structure 4 b. Further, the protrusion-shaped sheet-like fibrous structure 4 d is similarly disposed between the first sheet-like fibrous structure 4 a and the second sheet-like fibrous structure 4 b. The protrusion-shaped sheet-like fibrous structure 4 d is also formed from approximately the same material as that for the first sheet-like fibrous structure 4 a or the second sheet-like fibrous structure 4 b. Incidentally, in the cushion body 11 in this embodiment, the bank portion and the protrusion portion are formed using the U-shaped sheet-like fibrous structure 4 c and the protrusion-shaped sheet-like fibrous structure 4 d, but the bank portion or the protrusion portion may be formed utilizing the shape of the cavity 40 a without using these sheet-like fibrous structures.

Further, all of the first sheet-like fibrous structure 4 a, the second sheet-like fibrous structure 4 b, the U-shaped sheet-like fibrous structure 4 c, and the protrusion-shaped sheet-like fibrous structure 4 d are formed from the same fiber material. Therefore, when the cushion body 11 is discarded due to damage of the cushion body 11 or duration of life, separation thereof can be saved, so that recycling efficiency is improved.

Incidentally, in this embodiment, the example that one sheet-like fibrous structure 4 a and one sheet-like fibrous structure 4 b have been stacked as the cushion body 11 is shown, but regarding each of the fibrous structures, the number of stacks may be plural. In this case, it is preferable that the number of fibrous structures to be stacked is adjusted according to feeling, durability, size, or the like required for the cushion body 11.

Though the cushion body 11 has been explained above, a cushion body 21 for the seat back portion may be similarly formed by stacking the sheet-like fibrous structures. Regarding the cushion body 21, a direction in which load acts from the back of the seat occupant when a seat occupant sits is a thickness direction of the sheet-like fibrous structure constituting the cushion 21. Accordingly, in order to secure dispersibility of hardness or stress and durability in a stress direction, a three-dimensional shape can be achieved by stacking sheet-like fibrous structures in a direction in which stress acts and performing high pressure steam forming within the mold. Then, a seat 1 is formed by arranging the cushion bodies 11 and 21 thus formed on the sheet frames 15 and 25 and coating them with covers 13 and 23 (an assembling step).

In this embodiment, since also in the cushion body 21 of the seat back portion 20, the stacking direction of the web constituting the sheet-like fibrous structure is configured to extend along the widthwise direction of the cushion body 21 similarly to the cushion body 11 of the seat portion 10, the back of the seat occupant is supported as if being surrounded from both sides in the widthwise direction. As a result, the seat occupant can obtain a soft touch feeling.

Incidentally, when the cushion body 11 is formed, the cover 13, and the sheet-like fibrous structures 4 a to 4 d are stacked via hot-melt films, hot-melt unwoven clothes, hot-melt adhesives, or the like, and they are disposed in the mold 40, so that high pressure steam forming may be performed. Thereby, the cover 13 can be formed integrally with the cushion body 11. The cover 23 may be similarly handled.

If the high pressure steam molding is performed in a state that the sheet-like fibrous structures 4 a to 4 d are coated with the cover 13, the sheet-like fibrous structures 4 a to 4 d and the cover 13 are arranged in the mold 40, when the molding temperature is excessively high, the cover 13 may lose color. In this case, therefore, the molding temperature may be set to be lower than the melting temperature of the dye dyeing the cover 13.

Further, in the above embodiment, water vapor is blown to the mold 40, but the present invention is not limited to this treatment and heat conducting material which does not adversely affect fibers can be used. That is, steam of the selected heat conducting material can be blown to the mold 40 by raising pressure in the high pressure steam molding machine 50 such that a desired temperature is a boiling point of the selected heat conducting material.

Further, in the embodiment, the cushion body 11 is formed using the sheet-like fibrous structures 4 a to 4 d formed by folding the web 2 in an accordion shape as the fibrous structures, but the present invention is not limited to this constitution, and a fibrous structure obtained by stacking many webs 2 in the thickness direction can be used as the fibrous structure, or a raw fiber assembly obtained by dispersing and blending main fibers and binder fibers may be used.

Furthermore, in the embodiment, the cushion bodies 11 and 21 obtained by stacking the sheet-like fibrous structures 4 a to 4 d to perform the high pressure steam forming are used for the seat portion 10 and the seat back portion 20, but the present invention is not limited to this constitution, and a cushion body obtained by stacking sheet-like fibrous structures 4 a to 4 d to perform high pressure steam forming may be used at a portion on which load due to seat occupant sitting acts such as an arm rest or a head rest.

Next, details of a seat using the cushion body 11 will be explained. FIG. 11 includes sectional views showing a state where a seat portion of a seat has been cut in a widthwise direction, FIG. 11 (a) being a view showing the whole of the seat portion, and FIG. 11 (b) being a view showing a region circled in FIG. 11 (a) in an enlarged manner. As shown in FIG. 11 (a), the seat portion 10 includes a cushion body 11, a cover 13, and a seat frame 15. A surface of the cushion body 11 is coated with the cover 13, and as shown in FIG. 11 (b), a trim cord 17 made from resin is sewn to an end portion of the cover 13. The trim cord 17 is formed to have an about J shape in section, and a member such as a string can be hooked on a bent portion formed at a distal end of the trim cord 17. On the other hand, an engagement portion 19 is provided inside the seat frame 15 in a projecting manner. A wire is provided on the side of a distal end of the engagement portion 19. The cover 13 can be fixed to the seat frame 15 by hooking the bent portion of the trim cord 17 on the wire of the engagement portion 19.

Next, a method for manufacturing a seat portion 10 of a seat for a vehicle will be explained in detail. First, a hot-melt film is caused to adhere to a surface of the cushion body 11 before the high pressure steam forming, and the surface is coated with the cover 13. Next, the cushion body 11 whose surface is coated with the cover 13 is introduced into a high pressure steam molding machine, wherein high pressure steam molding is performed so that the cushion body 11 and the cover 13 are formed integrally.

The molded cushion body 11 is taken out of the high pressure steam molding machine, and it is left for a while to dry. After drying, the trim cord 17 made from resin is sewn on the end portion of the cover 13. Next, wrinkles of a surface of the seat portion 10 are removed by pulling the end portion of the cover 13 and the trim cord 17 is hooked to the engagement portion 19. The above is directed to explanation about the seat portion 10 of the seat 1, but the seat back portion 20 can also be manufactured according to similar steps. 

1. A seat comprising: a cushion body made from a fibrous structure, wherein the fibrous structure is obtained by stacking a web so that an extending direction of the web is along a thickness direction of the fibrous structure, wherein the thickness direction of the fibrous structure is along a direction of a load applied on the cushion body at sitting, and wherein a stacking direction of the web constituting the fibrous structure is along a widthwise direction of the cushion body, the cushion body having a first hardness at a load receiving face defining a sitting surface less than a second hardness at an opposing non-load receiving face of the cushion body; and, a seat frame supporting the cushion body.
 2. The seat according to claim 1, wherein the cushion body includes opposing side portions separated by a center portion along the widthwise direction, and wherein the cushion body is supported by the seat frame on the side portions.
 3. The seat according to claim 1, wherein the cushion body comprises a molded cushion body resulting from being molded by a mold having a cavity with a predetermined shape and by having steam blown to the fibrous structure through steam holes formed through the mold under barometrical pressure higher than atmospheric pressure.
 4. The seat according to claim 3, wherein the fiber structure comprises binder fibers and main fibers, and wherein the barometrical pressure is a saturated steam pressure at a temperature at or above a melting point of the binder fibers and lower than a melting point of the main fibers.
 5. The seat according to claim 1, wherein the cushion body comprises a molded cushion body resulting from blowing steam to the fibrous structure through steam holes through a side of a mold at a non-load receiving face of the cushion body.
 6. The seat according to claim 5, wherein the mold has more steam holes through the side of the mold at the non-load receiving face of the cushion body than through a side of the mold at a load receiving face of the cushion body. 